Battery pack upper cover and battery pack

Abstract

This utility model proposes a battery pack cover and a battery pack. The battery pack cover includes a cover body, which comprises an upper plate profile and a lower plate profile. The upper and lower plate profiles are arranged parallel to each other and are fixedly connected by multiple connecting structures. This utility model adopts a double-layer plate profile and multi-point connection structure design, which significantly improves the overall rigidity and impact resistance of the battery pack cover. The upper and lower plate profiles form a stable grid-like support frame through horizontally, vertically, and obliquely arranged reinforcing ribs, and can be optionally equipped with intermediate support structures such as honeycomb core material or foam filling, which effectively improves bending and torsional resistance, suppresses large-span deformation, and enhances top protection through structural energy absorption mechanism, solving the technical problems of insufficient rigidity, easy deformation, and poor impact resistance of traditional single-layer plate structures.

Description

Technical Field

[0001] This utility model belongs to the field of battery pack technology, specifically relating to a battery pack cover and a battery pack. Background Technology

[0002] In new energy vehicles, battery pack sizes are increasing, such as in CTB and long-range models, leading to a greater span for the battery pack cover. Therefore, traditional single-layer stamped plates or thin-walled covers suffer from the following problems: insufficient rigidity: prone to bending and deformation under bumpy driving conditions or rollovers, affecting sealing and safety; weak impact resistance: the top may bear falling objects or maintenance loads, making single-layer plates prone to dents or cracks; poor NVH performance: thin plates are prone to vibration and noise. Therefore, they cannot meet the requirements of current battery pack covers. Utility Model Content

[0003] In view of the above-mentioned shortcomings of the prior art, the purpose of this utility model is to provide a battery pack cover and a battery pack to solve the problem that the traditional single-layer stamped plate or thin-walled cover has insufficient rigidity, weak impact resistance and poor NVH performance due to the increasing size of the battery pack, which leads to the increase in the span of the battery pack cover. As a result, the cover cannot meet the requirements of the existing battery pack.

[0004] To achieve the above and other related objectives, this utility model proposes a battery pack cover, comprising: a cover body, the cover body including an upper plate profile and a lower plate profile, the upper plate profile and the lower plate profile being arranged parallel to each other, and the upper plate profile and the lower plate profile being fixedly connected by multiple connecting structures.

[0005] In one embodiment of this utility model, the upper plate profile and / or the lower plate profile are aluminum alloy profiles.

[0006] In one embodiment of the present invention, the connection structure includes a first connector, which is spaced between the upper plate profile and the lower plate profile for connecting the upper plate profile and the lower plate profile.

[0007] In one embodiment of the present invention, the connection structure further includes a second connector, which is spaced between the upper plate profile and the lower plate profile, and the second connector and the first connector are arranged crosswise.

[0008] In one embodiment of the present invention, the first connector and the second connector are spaced-apart reinforcing ribs, which are fixedly connected to the upper plate profile and the lower plate profile by one or more of welding, riveting or screwing.

[0009] In one embodiment of this utility model, the reinforcing ribs are arranged perpendicularly or obliquely to the upper plate profile.

[0010] In one embodiment of the present invention, an intermediate support structure is further filled between the upper plate profile and the lower plate profile, the intermediate support structure including honeycomb core material, foam filling material, corrugated plate or truss support frame.

[0011] In one embodiment of the present invention, the edge of the upper cover body is provided with an annular reinforcing frame, and the annular reinforcing frame is integrally formed or welded to the upper plate profile and the lower plate profile.

[0012] In one embodiment of this utility model, the annular reinforcing frame is provided with a sealing groove for airtight connection with the lower housing of the battery pack via a sealing ring.

[0013] This utility model also proposes a battery pack, including a lower shell and an upper cover mounted thereon, characterized in that the upper cover is a battery pack upper cover as described in any of the above embodiments, and the battery pack upper cover and the lower shell together form a closed battery cavity for accommodating multiple battery cells or battery modules.

[0014] This utility model proposes a battery pack cover and a battery pack, which have the following beneficial effects:

[0015] This invention significantly improves the overall rigidity and impact resistance of the battery pack cover by employing a double-layer plate profile and a multi-point connection structure. The upper and lower plate profiles are connected by horizontally, vertically, and obliquely arranged reinforcing ribs to form a stable grid-like support frame. Optional intermediate support structures such as honeycomb core materials or foam filling can be added, effectively improving bending and torsional resistance, suppressing large-span deformation, and enhancing top protection through a structural energy absorption mechanism. This solves the technical problems of insufficient rigidity, easy deformation, and poor impact resistance inherent in traditional single-layer plate structures.

[0016] This invention achieves excellent lightweight and NVH performance while maintaining high strength. Compared to a single-layer thick plate of equivalent strength, this solution can reduce weight by 30% to 50%, and effectively blocks vibration and noise transmission by utilizing a closed cavity and damping materials, thus improving the overall vehicle acoustic performance. The integrated design of the annular reinforcing frame and sealing groove further ensures connection reliability and airtightness. The overall structure is feasible in terms of manufacturing process and easy to integrate, making it suitable for large-size battery packs, and achieving synergistic optimization of structural strength and lightweight. Attached Figure Description

[0017] The accompanying drawings, which are incorporated in and form part of this specification, illustrate embodiments consistent with this application and, together with the description, serve to explain the principles of this application. It is obvious that the drawings described below are merely some embodiments of this application, and those skilled in the art can obtain other drawings based on these drawings without any inventive effort.

[0018] Figure 1 This is a schematic diagram of the structure of the battery pack cover in one embodiment of the present invention.

[0019] Figure 2 This is a partial cross-sectional schematic diagram of the battery pack cover in one embodiment of the present invention. Detailed Implementation

[0020] The following specific examples illustrate the implementation of this utility model. Those skilled in the art can easily understand other advantages and effects of this utility model from the content disclosed in this specification. This utility model can also be implemented or applied through other different specific embodiments. Various details in this specification can also be modified or changed based on different viewpoints and applications without departing from the spirit of this utility model. In the absence of conflict, the following embodiments and features in the embodiments can be combined with each other.

[0021] It should be noted that the illustrations provided in the following embodiments are only schematic representations of the basic concept of the present invention. The drawings only show the components related to the present invention and are not drawn according to the actual number, shape and size of the components. In actual implementation, the form, quantity and proportion of each component can be arbitrarily changed, and the layout of the components may also be more complex.

[0022] In the following description, numerous details are explored to provide a more thorough explanation of embodiments of the present invention. However, it will be apparent to those skilled in the art that embodiments of the present invention may be practiced without these specific details. In other embodiments, well-known structures and devices are shown in block diagram form rather than in detail to avoid obscuring embodiments of the present invention.

[0023] With the rapid development of new energy vehicle technology, power battery systems are constantly evolving towards higher energy density and longer driving range. The integrated design trend, represented by "cell-to-body" (CTB), is becoming increasingly popular. As part of the overall vehicle structure, the battery pack is significantly larger, especially the lateral span and longitudinal length of the battery pack cover, resulting in a larger coverage area and more complex structural stresses. Against this backdrop, traditional battery pack covers are mostly made of single-layer stamped steel plates or thin-walled aluminum alloy profiles. These structures have revealed several problems in the application of new, large-size battery packs, including the following:

[0024] Insufficient structural rigidity: Due to the increased span of the top cover, the single-layer thin plate structure is prone to mid-section displacement or bending deformation when subjected to road bumps, torsion conditions or rollover impacts during vehicle operation. This deformation not only affects the sealing surface fit between the top cover and the shell, which may lead to sealing failure, leakage or insulation risks, but may also squeeze the internal modules, threatening battery safety.

[0025] Weak resistance to localized impacts: During maintenance work, tools may fall or foreign objects may impact the top of the battery pack; in addition, the top cover needs to withstand a certain top load in the event of a collision or rollover. Traditional single-layer plate structures have poor dent resistance, are prone to localized dents or even cracks, reduce structural integrity, and increase the risk of thermal runaway.

[0026] Poor NVH performance: The low natural frequency of the single-layer thin plate structure makes it easy to couple with the road surface excitation frequency, resulting in resonance and structural noise such as "humming", which affects driving comfort, especially at high speeds or on uneven road surfaces.

[0027] The contradiction between lightweighting and structural strength is prominent: In order to improve stiffness and strength, the conventional approach is to increase the thickness of the sheet metal or select higher strength materials. However, this directly leads to an increase in the weight of the cover, which violates the lightweight design goal of "reducing weight and increasing efficiency" for new energy vehicles. At the same time, the increase in material usage also increases manufacturing costs.

[0028] Therefore, please refer to Figure 1 and Figure 2 As shown, this utility model proposes a battery pack cover that aims to address the shortcomings of traditional single-layer stamped plate or thin-walled profile covers in terms of rigidity, impact resistance, and NVH performance. This cover structure achieves high rigidity, strong impact resistance, and excellent acoustic characteristics through a double-layer plate profile design and multi-point connection structure, while maintaining lightweight advantages.

[0029] Please see Figure 1 and Figure 2As shown, in this embodiment, the upper cover structure 100 mainly includes an upper cover body 10, which includes an upper plate profile 11 and a lower plate profile 12. The upper plate profile 11 and the lower plate profile 12 are arranged parallel to each other and are fixedly connected by multiple connecting structures. The upper plate profile 11, as the outer surface of the upper cover, is directly exposed to the external environment and needs to have good corrosion resistance, aesthetics, and a certain degree of protection. The preferred material is high-strength aluminum alloy to ensure sufficient strength and rigidity. Its surface can be anodized or coated with an anti-corrosion coating as needed to improve weather resistance. The lower plate profile 12 is located inside the battery pack and mainly bears the pressure from the battery module and external loads, and plays a protective role for the internal components. It is also made of high-strength aluminum alloy or other lightweight high-strength materials, such as carbon fiber composite materials. Its thickness can be slightly greater than that of the upper plate profile to enhance the overall structural rigidity.

[0030] Please see Figure 1 and Figure 2 As shown, in this embodiment, the connecting structure 13 is distributed between the upper plate profile 11 and the lower plate profile 12, arranged at intervals along the longitudinal and transverse directions to form a stable support network. The connecting structure 13 includes a first connector, which is disposed between the upper plate profile 11 and the lower plate profile 12 to connect them, thereby increasing the overall bending and torsional stiffness and load-bearing capacity of the cover. Furthermore, the connecting structure 13 also includes a second connector, which is disposed between the upper plate profile 11 and the lower plate profile 12 to connect them, and the first and second connectors are arranged in a crisscross pattern. For example, the first connector extends along the width direction of the cover body, and the second connector extends along the length direction; the two intersect to form a grid-like support frame. This crisscross arrangement significantly enhances the overall bending and torsional stiffness and local load-bearing capacity of the cover.

[0031] Please see Figure 1 and Figure 2 As shown, in this embodiment, the first and second connecting members are spaced-apart reinforcing ribs, which are fixedly connected to the upper plate profile 11 and the lower plate profile 12 by one or more methods such as welding, riveting, or screwing. For example, the reinforcing ribs are thin plate structures, usually made of aluminum alloy or high-strength steel, and the spacing is set according to the structural strength requirements. The cross arrangement of the reinforcing ribs not only improves the structural rigidity but also forms multiple closed or semi-closed cavities, which helps to block the vibration propagation path and improve NVH performance.

[0032] In this embodiment, the reinforcing ribs and the upper plate profile 11 can be arranged perpendicularly, with the main body of the reinforcing ribs perpendicular to the surfaces of the upper plate profile 11 and the lower plate profile 12, forming a standard "T" or "I" shaped connection. This arrangement simplifies the structure, makes it easy to design and manufacture, effectively transmits vertical loads, and exhibits excellent compressive and bending resistance. Alternatively, the reinforcing ribs and the upper plate profile 11 can be arranged at an angle. For example, some or all of the reinforcing ribs may be angled relative to the upper plate profile 11, with an angle θ typically between 30° and 60°, preferably 45°. This angled structure alters the force transmission path, dispersing the load along the oblique direction, preventing stress concentration at the connection joint, reducing the risk of fatigue cracking, and under impact conditions, the angled ribs can absorb more energy through bending and buckling mechanisms, improving the impact resistance of the top cover. Of course, inclined reinforcing ribs can be combined with transverse and longitudinal ribs to form "X" or "K" shaped support structures, creating a more complex three-dimensional support network, which is particularly suitable for high-performance electric vehicles or application scenarios with extremely high structural safety requirements.

[0033] In this embodiment, an intermediate support structure is further filled between the upper plate profile 11 and the lower plate profile 12 to further improve the overall rigidity, impact resistance, and NVH performance of the upper cover. The intermediate support structure can be selected from one or more of the following materials / structural forms:

[0034] Honeycomb core material: Utilizing aluminum honeycomb, aramid paper honeycomb (Nomex), or composite honeycomb materials, it possesses extremely high specific stiffness and energy absorption capacity. The honeycomb cells are arranged in a regular hexagonal pattern, effectively resisting compressive, shear, and bending loads through structural stability. Upon impact from above, the honeycomb structure absorbs a large amount of energy through a layer-by-layer buckling mechanism, preventing the top cover from denting or cracking. Simultaneously, the hollow interior of the honeycomb structure helps to block sound wave propagation, significantly reducing vibration noise.

[0035] Foam filling material: Lightweight, high-strength structural foams such as polyurethane (PU) foam, epoxy resin foam, or aluminum-based metal foam are used. This material can be cast monolithically or pre-formed and then filled between double-layer boards, providing excellent cushioning, vibration damping, and sound insulation properties.

[0036] The aforementioned intermediate support structure can be used individually or in combination, depending on actual needs. For example, a honeycomb core material can be used in the central high-load area, while foam material can be filled in the edge areas to achieve an optimal balance between performance and cost. This design not only enhances the overall mechanical performance of the top cover but also achieves structural functionality integration without significantly increasing weight, making it particularly suitable for CTB architectures with long-range, large-size battery packs.

[0037] In this embodiment, an annular reinforcing frame 14 is provided on the edge of the upper cover body to improve the structural strength and connection reliability of the edge area of ​​the upper cover. The annular reinforcing frame 14 is continuously arranged circumferentially along the upper cover body and is located on the outer or inner side of the connection end of the upper plate profile 11 and the lower plate profile 12. In this embodiment, the annular reinforcing frame 14 is integrally formed or welded to the upper plate profile and the lower plate profile. The annular reinforcing frame 14 can enhance the edge stiffness, prevent the upper cover from warping under the preload of the assembly bolts or the vibration of vehicle operation, improve the load-bearing capacity of the connection area with the lower housing of the battery pack, ensure uniform stress on the sealing surface, and serve as the main connection interface, facilitating reliable fixation with the lower housing through bolts, clips, or other means.

[0038] In this embodiment, the annular reinforcing frame 14 is provided with a sealing groove for achieving an airtight connection with the lower housing of the battery pack via a sealing ring. The sealing groove is an annular groove formed on the bottom contact surface of the annular reinforcing frame 14, extending continuously along the circumference. Its cross-section can be rectangular, semi-circular, or trapezoidal, and its size is designed to match the sealing ring used. The sealing groove positions and limits the sealing ring, preventing it from shifting during assembly or operation. At the same time, the annular reinforcing frame 14 provides rigid support, ensuring that the sealing ring is subjected to consistent force along the circumference and avoiding local leakage. During assembly, the elastic sealing ring is embedded in the sealing groove. Then, the upper cover body is aligned with the lower housing of the battery pack and a pre-tightening force is applied, causing the sealing ring to undergo plastic deformation under pressure, filling the microscopic gaps between the connecting surfaces and forming a reliable airtight and liquid-tight barrier.

[0039] This utility model also proposes a battery pack, including a lower shell and an upper cover mounted thereon, characterized in that the upper cover and the lower shell together form a closed battery cavity for accommodating multiple battery cells or battery modules. The upper cover adopts any one of the battery pack upper covers described in the above embodiments, and will not be described again here to avoid repetition.

[0040] This utility model proposes a battery pack cover and battery pack, which significantly improves the overall rigidity of the cover through the design of double-layer plate profiles and intermediate connecting structure. Compared with single-layer plate structure, under the same mass conditions, the bending stiffness of double-layer plate structure can be increased by several times, effectively preventing bending deformation during vehicle operation and ensuring sealing and safety.

[0041] This invention proposes a battery pack cover and a battery pack. Compared to the traditional approach of simply increasing the thickness of a single-layer plate, the double-layer plate plus connecting structure significantly reduces weight while ensuring strength. For example, the cover using an aluminum alloy honeycomb sandwich structure is about 30% to 50% lighter than a single-layer thick plate of the same strength, and the manufacturing process is relatively mature, facilitating large-scale production and application.

[0042] In summary, the battery pack cover provided by this utility model, through its innovative double-layer plate profile and multi-point connection structure design, successfully solves the technical challenges of rigidity, impact resistance, and NVH performance in large-size battery pack covers, achieving a balance between lightweight and high strength.

[0043] The above embodiments are merely illustrative of the principles and effects of this utility model and are not intended to limit the scope of this utility model. Any person skilled in the art can modify or alter the above embodiments without departing from the spirit and scope of this utility model. Therefore, all equivalent modifications or alterations made by those skilled in the art without departing from the spirit and technical concept disclosed in this utility model should still be covered by the claims of this utility model.

Claims

1. A battery pack cover, characterized in that, include: The upper cover body includes an upper plate profile and a lower plate profile, which are arranged parallel to each other and are fixedly connected by multiple connecting structures.

2. The battery pack cover according to claim 1, characterized in that, The upper and / or lower plate profiles are aluminum alloy profiles.

3. The battery pack cover according to claim 1, characterized in that, The connection structure includes a first connector, which is spaced between the upper plate profile and the lower plate profile for connecting the upper plate profile and the lower plate profile.

4. The battery pack cover according to claim 3, characterized in that, The connection structure further includes a second connector, which is spaced between the upper plate profile and the lower plate profile, and the second connector and the first connector are arranged crosswise.

5. The battery pack cover according to claim 4, characterized in that, The first connector and the second connector are spaced-apart reinforcing ribs, which are fixedly connected to the upper plate profile and the lower plate profile by one or more of the following methods: welding, riveting or screwing.

6. The battery pack cover according to claim 5, characterized in that, The reinforcing ribs are arranged perpendicularly or obliquely to the upper plate profile.

7. The battery pack cover according to claim 1, characterized in that, An intermediate support structure is also filled between the upper and lower plate profiles. The intermediate support structure includes honeycomb core material, foam filling material, corrugated plate or truss support frame.

8. The battery pack cover according to claim 1, characterized in that, The edge of the upper cover body is provided with an annular reinforcing frame, which is integrally formed or welded to the upper plate profile and the lower plate profile.

9. The battery pack cover according to claim 8, characterized in that, The annular reinforcing frame is provided with a sealing groove for airtight connection with the lower housing of the battery pack via a sealing ring.

10. A battery pack, comprising a lower housing and an upper cover mounted thereon, characterized in that, The upper cover adopts the upper cover structure as described in any one of claims 1 to 9, and the upper cover and the lower housing together form a closed battery cavity for accommodating multiple battery cells or battery modules.

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